Wire holder and charging connector provided therewith

ABSTRACT

A clip ( 60 ) is mounted in a housing ( 11 ) of a charging connector ( 10 ). The clip ( 60 ) includes a box-shaped main body ( 61 ) formed by assembling two half members ( 62, 62 ). The main body ( 61 ) is prevented from moving in longitudinal and circumferential directions of a wire (W) relative to the housing ( 11 ) by the surface contact of the outer surface of the main body ( 61 ) with the inner surface of the housing ( 11 ). Wire insertion holes ( 67 ) are formed in the main body ( 61 ) by assembling the half members ( 62, 62 ) so that pairs of curved portions ( 66, 66 ) face each other. The wire (W) is held in the main body ( 61 ) by being tightly held by the curved portions ( 66, 66 ).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a wire holder used for a charging connector and to a charging connector provided therewith.

2. Description of the Related Art

U.S. Pat. No. 6,602,090 discloses a wire holder for a charging connector with a housing and a wire holder retained in the housing. The wire holder is a cylindrical member made of rubber and is formed with wire insertion holes. Wires are inserted through the wire insertion holes. A tightening member, such as a crimp ring, then is tightened over the entire circumference of the wire holder to hold the wires. The wire holding of U.S. Pat. No. 6,602,090 holds the wires only by producing frictional forces between the inner peripheral surfaces of the wire insertion holes and the outer peripheral surfaces of the wires. Thus, the wire cannot be held when pulled with a strong force exceeding the frictional force and there is a possibility of wire breakage in the housing. To increase a wire holding force, it is thought to strongly hold the wire, for example, using a wire holding clip. However, there is concern about damage to the wire and rotation of the wire holding member relative to the housing.

The invention was completed in view of the above situation and an object thereof is to prevent the damage of a wire.

SUMMARY OF THE INVENTION

The invention relates to a wire holder to be mounted in a housing of a charging connector. The wire holder comprises a substantially box-shaped main body formed by assembling two half members with each other. The main body is prevented from moving in longitudinal and/or circumferential directions of a wire relative to the housing by the surface contact of the outer surface of the main body with the inner surface of the housing. At least one wire insertion hole is formed through the main body for holding the wire. The wire insertion hole is formed by cutting concave curves in edges of the half members and then assembling the half members so that edges with the concave curves abut and so that the concave curves oppose one another to form the wire insertion hole. The concave curves are dimensioned to tightly hold the wire without damaging the wire. The inability of the wire holder to rotate relative to the housing also prevents damage to the wire.

The half members may be identical components. Thus, the types of components can be reduced and component cost can be reduced.

The curved portions ensure a substantially uniform pressing force on the wire, thereby further preventing damage to the wire.

One or more escaping portions may be provided at the opposite ends of the curved portion and incline radially outward of the wire insertion hole. Accordingly, parts of the wire can enter the escaping portions to prevent the damage even if the curved portions are pressed excessively against the outer peripheral surface of the wire while assembling the half members.

Two wire insertion holes may be coaxially arranged while being spaced apart in the longitudinal direction of the wire. Accordingly, pressing forces on the wire in the respective wire insertion holes can be reduced since the wire is held in the wire insertion holes at two positions. Thus, damage to the wire is even less likely.

The invention also relates to a charging connector with a housing, at least one wire drawn out from the housing, and the above-described holder for fixing the wire in the housing.

The housing may be formed integrally by fixing first and second half members to each other by bolting.

A connector connecting portion may be mounted in a front end of the housing and may be held tightly by the both half members. At least one positioning portion for positioning the half members may be provided at a position of the first half member distant from the connector connecting portion and contacts the inner surface of the other half member when the half members are assembled in proper postures.

The mounting portion substantially may be divided substantially bilaterally symmetrically by both half members and the mounting portions of the half members may be arranged to face each other when the half members assembled.

The positioning portion may be provided adjacent to the mounting portion.

The half members may be fixed to each other by bolting.

Bolt fastening portions may be arranged in the first half member and the positioning portion may be provided at a position to prevent the second half member from rotating upon receiving a force in a rotational direction as the bolt is tightened performed at the bolt fastening portion most distant from the connector connecting portion.

The positioning portion may be connected to a first opening edge of the first half member and the bolt fastening portion is connected to second opening edge substantially facing the first opening edge.

The housing may include a grip arranged behind the connector connecting portion and from which at least one wire may be drawn out. The positioning portion may be provided in the grip.

These and other objects, features and advantages of the present invention will become more apparent upon reading of the following detailed description of preferred embodiments and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a charging connector.

FIG. 2 is a side view of the charging connector.

FIG. 3 is a perspective view showing a state where a cover-side housing is removed in FIG. 1.

FIG. 4 is a perspective view showing only a base-side housing in FIG. 3.

FIG. 5 is a side view of a metal clip in FIG. 3 when viewed sideways.

FIG. 6 is a section showing the metal clip in FIG. 3 cut along a longitudinal direction of a wire to be divided into upper and lower parts when viewed sideways.

FIG. 7 is a section along A-A of FIG. 2.

FIG. 8 is a side view showing an inner surface side of the base-side housing.

FIG. 9 is a side view showing an inner surface side of the cover-side housing.

FIG. 10 is a section along B-B of FIG. 8.

FIG. 11 is a perspective view of a half member.

FIG. 12 is a plan view of the metal clip.

FIG. 13 is a side view of the metal clip.

FIG. 14 is a front view of the metal clip.

FIG. 15 is a section along C-C of FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A charging connector in accordance with the invention is identified generally by the number 10 and includes a housing 11 having a pistol shape. The housing 11 comprises a front housing 20 connectable to a vehicle-side connector (not shown). A base housing 30 and a cover housing 40 hold the front housing 20 from left and right sides. Further, as shown in FIG. 2, the base housing 30 and the cover housing 40 are fixed to one another by bolts B. It should be understood that the base housing 30 and the cover housing 40 may be fixed to one another by clips, retainers, latches, or similar coupling members.

As shown in FIG. 3, at least one wire W is held in a clip 60 housed in a grip 13 of the housing 11. The clip 60 preferably is made of metal The grip 13 extends rearward from a release button 52 and is aligned obliquely down with respect to a connecting direction CD of the front housing 20 to the vehicle-side connector. Note that a longitudinal direction of the wire W is referred to as forward and backward directions FBD and a draw-out direction of the wire W is referred to as a backward direction in the following description on the internal structures of the grip 13 and the clip 60.

The wire W is drawn out backward from the grip 13 and is to be connected to a household power supply. A battery (not shown) installed in a vehicle is to be charged by connecting the charging connector 10 to the vehicle-side connector.

A contact bush 15 is mounted in a draw-out opening of the grip 13 for the wire W. The contact bush 15 is made of a flexible or resilient material, such as flexible rubber material, and projects back from the rear end of the grip 13, as shown in FIG. 6. The contact bush 15 is to be positioned on the inner peripheral surface of the grip 13 while being retained in forward and backward directions FBD by mating engagement of one or more projections and one or more respective recesses. The wire W penetrates through the contact bush 15 to prevent damage by contact of the wire W with the rear end of the grip part 13 when the wire W is shaken in a vertical or lateral direction and provides sealing between the wire and the housing 11.

As shown in FIG. 3, a lever 50 is housed in the housings 30, 40 and a lock claw 51 is provided near the front end of the lever 50. The lock claw 51 projects forward in connection direction CD from the front end opening of the two housings 30, 40 and is out from the front housing 20. The lock claw 51 engages a lock projection (not shown) on the vehicle-side connector when the charging connector 10 is connected to the vehicle-side connector in the connecting direction CD so that the charging connector 10 and the vehicle-side connector are held in a connected.

On the other hand, the release button 52 is provided near the rear end of the lever 50. This release button 52 projects out through a release window 12 in an upper end corner of the grip 13. The lock claw 51 is displaced away from the first housing 20 when this release button 52 is pushed in. Thus, the lock claw 51 is released from its locked state and the charging connector 10 can be separated from the vehicle-side connector. This release button 52 is pushed down by the thumb while the grip 13 is gripped by the hand.

The front housing 20 is made e.g. of synthetic resin and is a forwardly open tube. Terminal accommodating portions 21 project forward in the front housing 20 along the connecting direction CD and also are in the form of tubes. Female terminals (not shown) are accommodated in the respective terminal accommodating portions 21. Small-diameter wires are connected to the female terminals by crimping and are bundled together in the housing 11 to form 13.

As shown in FIG. 3, an outwardly projecting flange 22 extends circumferentially around the rear end of the front housing 20. On the other hand, as shown in FIGS. 4 and 8, a base mounting groove 31 is provided near a front portion of the base housing 30 for receiving a circumferential part of the flange 22. Similarly, as shown in FIG. 9, a cover mounting groove 41 is provided near a front portion of the cover housing 40 for receiving the remaining circumferential part of the flange 22. Thus, the flange 22 is held from left and right sides by the mounting grooves 31, 41. The housings 30, 40 then are fastened by the bolts B to hold the front housing 20 tightly from left and right sides by the base housing 30 and the cover housing 40.

In this way, the front end of the housing 11 is in a backlash-free rigid state and defines a rigid body with no likelihood of displacing the housings 30, 40 when the base housing 30 and the cover housing 40 are assembled and fastened by the bolts B. However, unlike the front housing 20, there is no member firmly held in the grip 13. Thus, there is a concern that the housings 30, 40 may be displaced in a tightening direction of the bolts B when the bolts B are tightened.

Bolt fastening portions 35, 45 are provided in the housing 11. The bolt fastening portions 35, 45 most distant from the front housing 20 are provided near the contact bush 15 in the grip 13. Before the both housings 30, 40 are assembled, the bolt fastening portion 35 is connected to an opening edge of the base housing 30 in the grip 13 and the bolt fastening portion 45 is connected to an opening edge of the cover housing 40 in the grip 13, as shown in FIGS. 8 and 9. A force acting in a clockwise direction about the bolt fastening portion 45 may be produced in the cover housing 40 when the bolts B are fastened to the bolt fastening portions 35, 45. As a result, the opening edge located at a side opposite to the bolt fastening portion 45 may try to rotate toward the bolt fastening portion 35 of the base housing 30.

Accordingly, at least one positioning rib 16 is provided in the base housing 30 to properly position the cover housing 40, and particularly to prevent rotation or displacement of the cover housing 40. The positioning rib 16 is connected to the opening edge facing the opening edge where the bolt fastening portion 35 is provided and hence is as far as possible from the bolt fastening portion 35. Therefore, proper positioning is particularly effective and a force in a rotational direction is minimized. The positioning rib 16 projects from the opening edge of the base-side housing 30 into the interior of the cover housing 40. Thus, the positioning rib 16 is in contact with the inner surface of the cover housing 40 when the housings 30, 40 are assembled in proper postures to prevent rotation of the cover housing 40.

The clip 60 has a substantially box-shaped main body 61. A mounting portion where the main body 61 is to be mounted is provided in the housing 11. As can be understood from a comparison of FIGS. 8 and 9, this mounting portion is substantially bilaterally symmetrically divided by the base housing 30 and the cover housing 40 and the mounting portions of the base housing 30 and the cover housing 40 face each other when the housings 30, 40 are assembled.

As shown in FIG. 8, the mounting portion of the base housing 30 includes two base retaining portions 32, 32 for preventing forward and backward movements of the main body 61, two base restricting portions 33, 33 for preventing up and down movements of the main body 61 and two base tight holding portions 34, 34 for preventing left and right movements of the main body 61. On the other hand, the mounting portion of the cover housing 40 includes two cover retaining portion 42, 42 for preventing forward and backward movements of the main body 61, two cover restricting portions 43, 43 for preventing up and down movements of the main body 61 and two cover tight holding portions 44, 44 for preventing left and right movements of the main body 61. Here, vertical and lateral directions refer to the orientation in FIG. 7.

The base retaining portions 32, 32 and the cover retaining portions 42, 42 are substantially plate-like and are held in substantially surface contact with the front and rear surfaces of the main body 61, as shown in FIG. 6 to prevent the inclination of the main body 61 while preventing forward and backward movements of the main body 61. Further, a passage hole 14 is formed between the base-side retaining portions 32, 32 and the cover-side retaining portions 42, 42 for receiving the wire W.

As shown in FIGS. 8 and 9, each of the base tight holding portions 34 and the cover tight holding portions 44 has a front-back rib extending in forward and backward directions FBD and a vertical rib extending in the vertical direction (substantially normal to the forward and backward directions FBD). Specifically, two front-back ribs are substantially parallel and two vertical ribs are arranged in series. As shown in FIG. 7, the base tight holding portions 34 and the cover tight holding portions 44 are substantially in line contact with the left and right surfaces of the main body 61 and/ prevent inclination and lateral movements of the main body 61.

The base restricting portions 33, 33 and the cover restricting portions 43, 43 all are substantially plate-like and facing parts of the base restricting portions 33 and the cover restricting portions 43 are spaced apart by a specified distance in the lateral direction, as shown in FIG. 7. Further, the base restricting portions 33, 33 are in substantially surface contact with the upper and lower surfaces of the main body 61 to prevent inclination of the main body 61 and to prevent up and down movements of the main body 61. On the other hand, the cover restricting portions 43, 43 are in substantially surface contact with the upper and lower surfaces of the main body 61 to prevent inclination of the main body 61 and to prevent up and down movements of the main body 61. That is, the main body 61 of the clip 60 is held so as not to rotate or incline relative to the housing 11 and is prevented from moving vertically, laterally and longitudinally.

The rear retaining portions 32, 42 are connected to the bolt fastening portions 35, 45. Recesses 36, 46 are formed at the front and rear sides of the bolt fastening portions 35, 45 on the opening edges of the housings 30, 40. Front and rear water drainage holes are formed near the base recesses 36 and the cover recesses 46 when the housings 30, 40 are assembled. Thus, water that may have entered the interior of the grip 13 is discharged to the outside through the water drainage holes.

The main body 61 of the clip 60 is formed by assembling half members 62 shown in FIG. 11 with each other. The half members 62 are identical components and each includes a bottom wall 63. A front wall 64F and a rear wall 64R stand up from the front and rear edges of the bottom wall 63 while substantially facing each other, and left and right side walls 65L, 65R stand up from the left and right edges of the bottom wall 63 while substantially facing each other. Openings 63B are formed at four corners of the bottom wall 63. Thus, water that may have entered the interior of the main body 61 can be discharged to the outside by the openings 63B.

As shown in FIG. 13, a substantially round hole 63A penetrates the center of the bottom wall 63. The holes 63A, 63A are coaxial when the half members 62, 62 are assembled, as shown in FIG. 13. Further, the base tight holding portions 34 and the cover tight holding portions 44 hold the bottom wall 63 tightly from left and right sides, as shown in FIG. 7. Grooves 34A, 44A are formed at positions of the tight holding portions 34, 44 corresponding to the round holes 63A, 63A. In this way, water that may have entered the interior of the main body 61 of the clip 60 can be discharged to the outside via the holes 63A, the grooves 34A, 44A and the recesses 36, 46.

As shown in FIG. 14, end edges of the front walls 64A face each other and butt each other from left and right sides. The butting edge of each front wall 64A, 64A each includes an arcuate curved portion 66. The curved portions 66, 66 face each other when the two half members 62, 62 are assembled to define a wire insertion hole 67 through which the wire W is inserted. The curved portions 66, 66 engage and resiliently press the wire W, as shown in FIG. 6, without damaging the insulation coating of the wire W. Thus, the metal clip 60 firmly retains the wire W without damage to the wire W.

Escaping portions 68 are provided at the opposite ends of each curved portion 66 and incline radially out of the wire insertion hole 67, as shown in FIG. 14. Escaping spaces are formed in areas sandwiched between the escaping portions 68 and communicate with the wire insertion hole 67 when the half members 62 are assembled. The wire W can escape into the escaping spaces when held excessively tightly by the curved portions 66. Further, the front and rear walls 64F, 64R are deformed away from each other with the bottom wall 63 as a center when the curved portions 66 are pressed firmly against the wire W so that a pressing force acting on the wire W can be relaxed, thereby further assuring that the curved portions 66 will not damage the wire W.

As shown in FIG. 14, the wire insertion holes 67 are coaxial and spaced apart in the longitudinal direction of the wire W. Thus, pressing forces on the wire W are less than if the wire W was held only by one wire insertion hole 67.

A positioning projection 69 is provided on one end of each of the butting edges of the front walls 64F, 64F, and a step 70 for receiving the mating positioning projection 69 is on the other end. The positioning projections 69 fit in the steps 70 and lock in the vertical direction to prevent displacements of the assembled half members 62, 62.

A locking hole 71 penetrates through one of the left and right side walls 65L, 65R, and a resiliently deformable locking piece 72 is provided at the other by cutting and bending. The locking piece 72 of the one half member 62 fits in the locking hole 71 of the other half member 62 when the half members 62, 62 are assembled so that the tip of the locking piece 72 engages the inner surface of the locking hole 71, as shown in FIG. 15, to retain the half members 62, 62. Note that, with the locking pieces 72 fit in the locking holes 71, the positioning projections 69 and the steps 70 come into contact if there is an attempt to separate the locking pieces 72 from the locking holes 71 in a direction perpendicular to an assembling direction of the half members 62, 62. Thus the locking pieces 72 are held in the locking holes 71 and the both half members 62, 62 are held assembled.

The front housing 20 and the lever 50 are assembled with the base-side housing 30. Additionally, the wire W is supported by both curved portions 66 of one half member 62 of the clip 60. The two half members 62 then are assembled to one another to hold the wire W tightly by the curved portions 66, 66 of the half members 62, 62. In this way, the clip 60 is fixed to the wire W.

Subsequently, the clip 60 is mounted in a proper posture between the two base retaining portions 32, 32 in the grip 13 and between the both base restricting portions 33, 33 in the grip 13. In this state, the front and rear walls 64F, 64R of the half member 62 are in substantially surface contact with the base retaining portions 32, 32, the left and right side walls 65L, 65R of the half member 62 are in substantially surface contact with the both base restricting portions 33, 33 and the bottom wall 63 of the half member 62 is in substantially line contact with the base tight holding portions 34. The half members 62 then are assembled so that the curved portions 66, 66 press the wire W. The locking pieces 72, 72, which had been resiliently deformed by the lateral side walls 65L, 65R, return resiliently upon reaching proper mount positions and fit into the locking holes 71, 71. In this way, the two half members 62, 62 are assembled to form the main body 61, and this main body 61 is fixed to the wire W.

The cover housing 40 then is assembled with the base housing 30. Thus, the flange 22 of the front housing 20 is fit into the mounting grooves 31, 41 of the housings 30, 40 and the front housing 20 is held tightly by both housings 30, 40. Subsequently, the bolts B are tightened into the bolt fastening portions 35, 45. The cover housing 40 may try to rotate in a clockwise direction as the bolts B are tightened into the bolt fastening portions 35, 45 in the grip 13 due to a torque produced at the time of tightening. However, the inner surface of the cover housing 40 contacts the positioning ribs 16 of the base housing 30 to prevent rotation of the cover housing 40. The charging connector 10 is completed by tightening the bolts B.

As described above, in this embodiment, the main body 61 of the (metal) clip 60 particularly is retained by being held from front and/or rear side(s) by the retaining portions 32, 42, held from upper and/or lower sides by the restricting portions 33, 43 and/or held from lateral (left and/or right) side(s) by the tightly holding portions 34, 44. Accordingly, the rotation of the main body 61 of the metal clip 60 about the axis of the wire W and/or its displacement in the grip part 13 is/are prevented and the main body 61 particularly is retained in the longitudinal direction of the wire W. Further, since the wire W particularly can be uniformly pressed by the curved portions 66, 66, the damage of the wire W can be prevented. Furthermore, since the escaping portions 68 particularly are provided to allow the wire W to partly escape and a pair of front and rear wire insertion holes 67 are provided, a pressing force acting on the wire W can be reduced and the damage of the wire W can be further prevented.

As described above, the cover housing 40 may try to rotate in the clockwise direction about the bolt fastening portion 35 when the bolt B is tightened. However, the positioning rib 16 is provided on the opening edge at the side opposite to the bolt fastening portion 35 in the grip 13. The positioning rib 16 contacts the inner surface of the cover housing 40 to prevent rotation of the cover housing 40. Thus, it is sufficient to provide the positioning ribs 16 only in the base housing 30 and it is not necessary to provide the cover housing 40 with a displacement preventing mechanism. Thus, the housings 30, 40 can be positioned without being subject to spatial restriction. Further, the positioning ribs 16 are provided at the position distant from the bolt fastening portion 35 so that a force acting on the positioning rib 16 in a rotational direction can be minimized.

The invention is not limited to the above described embodiment. For example, the following embodiments also are included in the scope of the invention.

The metal clip 60 is used as the wire holding member in the above embodiment. However, a clip made of resin may be used according to the invention. In this case, two half members may be linked by a flexible hinge.

Although the curved portions are arcuate in the above embodiments, the shape of the curved portions is not limited to the arcuate shape according to the present invention and another curved shape may be adopted provided that the curved portions having such a shape can tightly hold the wire W.

Two escaping portions 68, 68 are provided at opposite ends of the curved portion 66 in the above embodiment. However, an escaping portion may be provided in the center of the curved portion according to the invention.

Front and rear wire insertion holes 67, 67 are provided in the main body 61. However, only one wire insertion hole may be provided according to the present invention. 

1. A wire holder (60) to be mounted in a housing (11) of a charging connector (10), the wire holder (60) comprising: two half members (62) assembled with each other to form a main body (61), the half members (62) having butting edges formed with curved portions (66) facing one another and forming at least one wire insertion hole (67) therebetween, the curved portions (66) of the wire insertion hole (67) being configured for tightly holding the wire (W).
 2. The wire holder of claim 1, wherein the half members (62) are identical.
 3. The wire holding member of claim 2, wherein the curved portions (66) are arcuate.
 4. The wire holder of claim 1, wherein escaping portions (68) are provided at the opposite ends of the curved portion (66) and incline radially outward of the wire insertion hole (67).
 5. The wire holder of claim 1, wherein the at least one wire insertion hole (67) comprises two wire insertion holes (67) coaxially arranged while being spaced apart in a longitudinal direction of the wire (W).
 6. A charging connector (10) comprising: a housing (11); at least one wire (W) drawn out from the housing (11); and a wire holder (60) mounted in the housing (11), the wire holder (60) having two half members (62) assembled with each other to form a main body (61), the half members (62) having butting edges formed with curved portions (66) facing one another and forming at least one wire insertion hole (67) therebetween, the curved portions (66) of the wire insertion hole (67) being configured for tightly holding the wire (W), the main body (61) being prevented from moving in longitudinal and circumferential directions of a wire (W) relative to the housing (11) by an surface contact of the outer surface of the main body (61) with an inner surface of the housing (11).
 7. The charging connector of claim 6, wherein the housing (11) is integrally formed by fixing first and second half members (30, 40) to each other.
 8. The charging connector of claim 7, further comprising a connector connecting portion (20) mounted in a front end portion of the housing (11) and tightly held by the both half members (30, 40); and at least one positioning portion (16) for positioning the half members (30, 40) is provided at a position of one half member (30) distant from the connector connecting portion (20) and contacts the inner surface of the other half member (40) when the half members (30, 40) are assembled in proper postures.
 9. The charging connector of claim 8, wherein the mounting portion is divided substantially bilaterally symmetrically by both half members (30, 40) and the mounting portion of the half members (30, 40) are arranged to substantially face each other with the half members (30, 40) assembled.
 10. The charging connector of claim 8, wherein the positioning portion (16) is provided adjacent to the mounting portion.
 11. The charging connector of claims 6, wherein the half members (30, 40) are fixed to each other by bolting.
 12. The charging connector of claim 11, wherein a plurality of bolt fastening portions (35) are arranged in the one half member (30); and wherein the positioning portion (16) is provided at a position to prevent the other half member (40) from rotating upon receiving a force in a rotational direction produced as the bolting is performed at the bolt fastening portion (35) arranged at a position most distant from the connector connecting portion (20).
 13. The charging connector of claim 12, wherein the positioning portion (16) is connected to one opening edge of the one half member (30) and the bolt fastening portion (35) is connected to another opening edge substantially facing the one opening edge.
 14. A charging connector of claim 6, wherein the housing (10) includes a grip (13) arranged behind the connector connecting portion (20) and from which the wire (W) is drawn out; and the positioning portion (16) is provided in the grip (13). 